Junction box

Abstract

The utility model discloses a junction box, which relates to the field of solar photovoltaic technology and comprises an upper cover and a lower cover. The lower cover is detachably connected with the upper cover, the lower cover is provided with an installation cavity and an air groove communicated with the installation cavity, the installation cavity is used for installing a solar panel intelligent controller, and the air groove is used for glue pouring and heat dissipation. According to the technical scheme provided by the utility model, the heat dissipation capability of the junction box can be improved, so that the reliability of the junction box during operation is improved.

Description

Technical Field

[0001] This utility model relates to the field of solar photovoltaic technology, and in particular to a junction box. Background Technology

[0002] With the rapid development of solar photovoltaic technology, the power output of photovoltaic modules is constantly increasing, making power loss and heat generation issues in junction boxes increasingly significant during operation. As a key component connecting solar panels to external circuits, the electrical components inside the junction box generate heat during current transmission. When the power output of photovoltaic modules increases, the heat accumulation inside the junction box intensifies, potentially leading to overheating, performance degradation, or even damage to components, thus affecting the stability and lifespan of the entire photovoltaic system.

[0003] Furthermore, junction boxes are typically installed outdoors, exposed to harsh environments such as high temperatures and direct sunlight for extended periods, further exacerbating the difficulty of heat dissipation. Therefore, effectively addressing the heat dissipation problem of junction boxes to ensure their reliability and stability during high-power operation has become a critical technical challenge that urgently needs to be solved in photovoltaic system design. Utility Model Content

[0004] The main purpose of this utility model is to propose a junction box that improves the heat dissipation capacity of the junction box, thereby improving the reliability of the junction box during operation.

[0005] To achieve the above objectives, this utility model proposes a junction box, the junction box comprising:

[0006] Top cover; and

[0007] The lower cover is detachably connected to the upper cover. The lower cover has a mounting cavity and an air groove communicating with the mounting cavity. The mounting cavity is used to install the solar panel smart controller, and the air groove is used for potting adhesive and heat dissipation.

[0008] In one embodiment, the air groove is an elongated arc-shaped groove.

[0009] In one embodiment, the lower cover is further provided with a plurality of hollow structures communicating with the mounting cavity, and the plurality of hollow structures are spaced apart from the air groove, the hollow structures being used for potting adhesive for heat dissipation.

[0010] In one embodiment, a plurality of the hollow structures are arranged sequentially around the periphery of the lower cover.

[0011] In one embodiment, the hollow structure includes at least three partitions connected in sequence. The three partitions are disposed on the inner wall of the lower cover and together with the inner wall of the lower cover form a glue-filling groove.

[0012] In one embodiment, the lower cover is further provided with a plurality of wiring holes communicating with the mounting cavity. The plurality of wiring holes are arranged along the same straight line and are spaced apart from the air groove.

[0013] In one embodiment, the upper cover has at least two insertion protrusions on one side, and the two insertion protrusions are spaced apart; the lower cover has an insertion hole on one side of its outer wall, and each insertion protrusion is inserted into one insertion hole; the side of the upper cover away from the insertion protrusions is hinged to the side of the lower cover away from the insertion hole.

[0014] In one embodiment, the upper cover has at least two mounting protrusions on the side away from the insertion protrusion, and the two mounting protrusions are spaced apart.

[0015] A handle is provided on the side of the lower cover away from the insertion hole, and mounting holes are provided at both ends of the handle. Each mounting protrusion is hinged to a mounting hole.

[0016] In one embodiment, the bottom of the lower cover is provided with two limiting protrusions for installing the solar panel smart controller. The two limiting protrusions are symmetrically arranged to limit the two sides of the solar panel smart controller.

[0017] In one embodiment, the bottom of the lower cover is further provided with a plurality of limiting posts, which are arranged at intervals, and each limiting post is used to be inserted into the solar panel intelligent controller.

[0018] The junction box of this utility model includes an upper cover and a lower cover; the lower cover is detachably connected to the upper cover, and the lower cover has a mounting cavity and an air groove communicating with the mounting cavity. The mounting cavity is used to install the solar panel intelligent controller, and the air groove is used for potting adhesive and heat dissipation. The design of the air groove in the junction box not only improves the quality of potting adhesive but also provides an efficient channel for heat dissipation. Combined with the integration of the intelligent controller, this junction box can maintain stable performance during high-power operation, significantly improving the reliability and operating efficiency of the entire photovoltaic system. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0020] Figure 1 A schematic diagram of the structure of an embodiment of the junction box provided by this utility model;

[0021] Figure 2A schematic diagram of the structure of the top cover of the junction box provided by this utility model;

[0022] Figure 3 This is a schematic diagram of the structure of the lower cover of the junction box provided by this utility model.

[0023] Explanation of icon numbers:

[0024] 10. Top cover; 11. Insertion protrusion; 12. Mounting protrusion; 20. Bottom cover; 20a. Mounting cavity; 20b. Air groove; 21. Hollow structure; 211. Partition; 211a. Glue potting groove; 20c. Wiring hole; 20d. Insertion hole; 22. Handle; 23. Limiting protrusion; 24. Limiting post.

[0025] The realization of the purpose, functional features and advantages of this utility model will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0026] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present utility model.

[0027] It should be noted that if the embodiments of this utility model involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indicators will also change accordingly.

[0028] Furthermore, if the embodiments of this utility model involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the use of "and / or" or "and / or" throughout the text includes three parallel solutions. For example, "A and / or B" includes solution A, solution B, or a solution where both A and B are satisfied simultaneously. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this utility model.

[0029] This utility model proposes a junction box.

[0030] Please see Figures 1 to 3 In one embodiment of the present invention, the junction box includes an upper cover 10 and a lower cover 20; the lower cover 20 is detachably connected to the upper cover 10, and the lower cover 20 is provided with an installation cavity 20a and an air groove 20b communicating with the installation cavity 20a. The installation cavity 20a is used to install the solar panel smart controller, and the air groove 20b is used for potting glue and heat dissipation.

[0031] The upper cover 10 and the lower cover 20 are connected by a detachable connection, such as by clips, screws, or hinges. This design allows the junction box to be easily opened before potting, facilitating the debugging of the internal circuitry and the installation of components. The detachable design of the upper cover 10 improves the maintainability of the junction box and also facilitates the inspection and adjustment of the internal structure during potting.

[0032] The lower cover 20 has a mounting cavity 20a inside to accommodate the solar panel intelligent controller, such as MPPT circuits and voltage regulator circuits. The size and shape of the mounting cavity 20a are optimized according to the specifications of the intelligent controller to ensure that the controller can be stably installed within it. The mounting cavity 20a provides physical support and protection for the intelligent controller, while reserving sufficient space to accommodate circuit boards and components of different sizes, enhancing the versatility and adaptability of the junction box. The mounting cavity 20a provides sufficient space for the PCB circuit of the solar panel intelligent controller, even accommodating large capacitors such as 8*10.

[0033] Air groove 20b communicates with mounting cavity 20a and is located at the bottom or side of lower cover 20. The design of air groove 20b allows the potting compound to flow fully during potting, and simultaneously, during junction box operation, air groove 20b acts as a heat dissipation channel, promoting airflow. The air groove 20b significantly improves the junction box's heat dissipation capacity. During potting, air groove 20b ensures uniform filling of the compound, preventing air bubbles and thus improving potting quality. During operation, air groove 20b acts as a heat dissipation channel, accelerating heat dissipation, effectively reducing the internal temperature of the junction box, and extending component lifespan.

[0034] The intelligent controller, integrated within the mounting cavity 20a, may include single or dual MPPT circuits, as well as power detection circuits. These circuits optimize the power output of the solar panels, ensuring they always operate at their maximum power point. By integrating the intelligent controller, the junction box not only optimizes power output but also monitors and adjusts the power status in real time during operation. This intelligent design improves the junction box's operating efficiency and reliability while reducing the risk of failure due to overheating or overload.

[0035] During the assembly of the junction box, the intelligent controller is first installed into the mounting cavity 20a of the lower cover 20. Then, potting compound is applied through the air channel 20b. Guided by the air channel 20b, the potting compound evenly fills the gap between the lower cover 20 and the intelligent controller, ensuring the sealing and stability of the internal components. After potting, the upper cover 10 and the lower cover 20 are detachably connected to form a complete junction box. During operation, the intelligent controller optimizes the power output of the solar panel, while the generated heat is dissipated through the air channel 20b. The heat dissipation channel design of the air channel 20b promotes airflow and accelerates heat dissipation, effectively reducing the internal temperature of the junction box. This heat dissipation design not only improves the reliability of the junction box during high-power operation but also extends its service life.

[0036] Through the above design, the air slot 20b of the junction box of this utility model not only improves the quality of potting but also provides an efficient channel for heat dissipation. Combined with the integration of an intelligent controller, this junction box can maintain stable performance during high-power operation, significantly improving the reliability and operating efficiency of the entire photovoltaic system.

[0037] In one embodiment, please refer to Figures 1 to 3 Air trough 20b is an elongated arc-shaped trough.

[0038] The air slot 20b is a special structure inside the lower cover 20 of the junction box, typically in the shape of an elongated arc. This design creates a continuous channel within the junction box, facilitating airflow and heat dissipation. The elongated arc-shaped air slot 20b not only increases the heat dissipation area but also optimizes the airflow path, improving heat dissipation efficiency.

[0039] In one embodiment, please refer to Figures 1 to 3 The lower cover 20 is also provided with multiple hollow structures 21 that communicate with the mounting cavity 20a. The multiple hollow structures 21 are spaced apart from the air grooves 20b. The hollow structures 21 are used for potting and heat dissipation.

[0040] In this embodiment, the lower cover 20 of the junction box not only has a mounting cavity 20a and an air groove 20b, but also features a plurality of perforated structures 21 communicating with the mounting cavity 20a. The perforated structures 21 are multiple through holes or open areas on the lower cover 20, communicating with the mounting cavity 20a but spaced apart from the air groove 20b. These perforated structures 21 are distributed on the bottom or sides of the lower cover 20 for potting and heat dissipation. The perforated structures 21 further increase the heat dissipation area while providing more flow paths for the potting compound. This design not only improves heat dissipation efficiency but also ensures that the compound can be filled more evenly, enhancing the sealing and stability of the junction box.

[0041] First, install the intelligent controller into the mounting cavity 20a of the lower cover 20, ensuring it is secure and the relevant circuits are connected. Then, potting compound is applied through the air groove 20b and the perforated structure 21. The potting compound flows from the air groove 20b into the mounting cavity 20a and further diffuses through the perforated structure 21, ensuring the compound evenly fills the entire cavity while avoiding air bubbles. After potting, the upper cover 10 and lower cover 20 are detachably connected to form a complete junction box.

[0042] The synergistic design of the air trough 20b and the hollow structure 21 not only improves the uniformity and quality of the potting compound but also significantly enhances heat dissipation. This design enables the junction box to maintain stable performance during high-power operation, significantly improving the reliability and operating efficiency of the entire photovoltaic system while extending the service life of the junction box.

[0043] In one embodiment, please refer to Figures 1 to 3 Multiple hollow structures 21 are arranged sequentially around the periphery of the lower cover 20.

[0044] The perforated structure 21, arranged sequentially around the perimeter of the lower cover 20, not only increases the heat dissipation area but also ensures uniform filling of the potting compound. This design enables the junction box to maintain stable performance during high-power operation, significantly improving the reliability and operating efficiency of the entire photovoltaic system while extending the junction box's lifespan. Furthermore, the surrounding perforated structure 21 enhances the overall structural strength of the junction box, making it better suited to complex outdoor environments.

[0045] In one embodiment, please refer to Figures 1 to 3 The hollow structure 21 includes at least three partitions 211 connected in sequence. The three partitions 211 are disposed on the inner wall of the lower cover 20 and enclose the inner wall of the lower cover 20 to form a glue-filling groove 211a.

[0046] The partition 211 is a thin sheet-like structure disposed on the inner wall of the lower cover 20. At least three partitions 211 are connected in sequence to form a closed or semi-closed glue-filling groove 211a. The height and spacing of the partitions 211 are optimized according to heat dissipation requirements and the glue-filling process. The partitions 211 not only increase the structural strength of the lower cover 20, but also provide a clear flow path for the glue by enclosing it to form the glue-filling groove 211a, preventing the glue from overflowing or accumulating in unwanted locations. This design significantly improves the uniformity and quality of glue filling.

[0047] The potting groove 211a is a cavity formed by the partition 211 and the inner wall of the lower cover 20, located inside the lower cover 20 and communicating with the mounting cavity 20a. The shape and size of the potting groove 211a are optimized according to the layout and heat dissipation requirements of the intelligent controller. The potting groove 211a provides a clear flow path for potting, ensuring that the potting compound can evenly fill the entire mounting cavity 20a while avoiding the generation of air bubbles. The potting groove 211a also increases the heat dissipation area, allowing heat to be quickly conducted to the surface of the lower cover 20 through the compound, further optimizing heat dissipation performance.

[0048] The glue-pouring groove 211a formed by the partition 211 and the inner wall of the lower cover 20 not only provides a clear flow path for glue pouring, avoiding glue overflow and the generation of air bubbles, but also increases the heat dissipation area, enabling heat to be quickly conducted and dissipated.

[0049] In one embodiment, please refer to Figures 1 to 3 The lower cover 20 is also provided with multiple wiring holes 20c that communicate with the mounting cavity 20a. The multiple wiring holes 20c are arranged along the same straight line and are spaced apart from the air groove 20b.

[0050] In this embodiment, the wiring holes 20c are multiple through holes on the lower cover 20, used to connect external circuits and the intelligent controller inside the mounting cavity 20a. These wiring holes 20c are arranged in a straight line to facilitate electrical connection, and are spaced apart from the air slots 20b to prevent the heat dissipation channel from being blocked by the wiring holes 20c. The design of the wiring holes 20c optimizes the convenience and reliability of electrical connection, while the spacing between them and the air slots 20b ensures unobstructed heat dissipation channels, further improving heat dissipation efficiency.

[0051] In one embodiment, please refer to Figures 1 to 3 The upper cover 10 has at least two insertion protrusions 11 on one side, and the two insertion protrusions 11 are spaced apart; the lower cover 20 has an insertion hole 20d on one side of its outer wall, and each insertion protrusion 11 is inserted into an insertion hole 20d; the side of the upper cover 10 away from the insertion protrusions 11 is hinged to the side of the lower cover 20 away from the insertion hole 20d.

[0052] In this embodiment, the plug-in protrusion 11 is a protruding part on the upper cover 10, typically a columnar or block-shaped structure, used to mate with the plug-in hole 20d of the lower cover 20. The size and shape of the plug-in protrusion 11 are designed according to the specifications of the plug-in hole 20d to ensure a tight fit between the two. The lower cover 20 is the bottom supporting component of the junction box, and has an internal mounting cavity 20a for mounting electrical components such as intelligent controllers. One outer wall of the lower cover 20 has a plug-in hole 20d that mates with the plug-in protrusion 11. The design of the plug-in hole 20d allows the lower cover 20 to be quickly connected to the upper cover 10 while ensuring a tight fit between the two.

[0053] The upper cover 10 has at least two interlocking protrusions 11 on one side, which are spaced apart. The lower cover 20 has corresponding interlocking holes 20d on one side of its outer wall, with each protrusion 11 precisely inserted into one hole 20d. The design of the interlocking protrusions 11 makes the connection between the upper cover 10 and the lower cover 20 more secure, while also facilitating quick assembly and disassembly. This design improves the maintainability of the junction box, allowing for quick opening of the upper cover 10 for debugging or repairing internal components when needed.

[0054] The upper cover 10 and the lower cover 20 are connected by a hinge, which is typically located on the side of the upper cover 10 and the lower cover 20 away from the insertion protrusion 11 and the insertion hole 20d. This design allows the upper cover 10 to open and close freely around the hinge. The hinge connection not only facilitates the assembly and disassembly of the junction box but also makes the connection between the upper cover 10 and the lower cover 20 more flexible. This design improves the maintainability of the junction box, allowing for quick opening of the upper cover 10 for debugging or repair of internal components when needed.

[0055] The junction box of this invention features structural optimization. The mating design of the insertion protrusion 11 and the insertion hole 20d, combined with the hinged connection between the upper cover 10 and the lower cover 20, not only improves the assembly and disassembly efficiency of the junction box but also enhances its sealing performance and overall structural strength. This design enables the junction box to maintain stable performance in complex outdoor environments, significantly improving the reliability and operating efficiency of the entire photovoltaic system while reducing maintenance costs.

[0056] In one embodiment, please refer to Figures 1 to 3 The upper cover 10 has at least two mounting protrusions 12 on the side away from the insertion protrusion 11, and the two mounting protrusions 12 are spaced apart; the lower cover 20 has a handle 22 on the side away from the insertion hole 20d, and the handle 22 has mounting holes at both ends, and each mounting protrusion 12 is hinged to a mounting hole.

[0057] Mounting protrusion 12 is a protruding part on the upper cover 10, typically a columnar or block-shaped structure, used to mate with the mounting hole on the handle 22 of the lower cover 20. The size and shape of the mounting protrusion 12 are designed according to the specifications of the mounting hole to ensure a tight fit. The mating of the mounting protrusion 12 with the mounting hole not only provides a mechanical connection but also enhances the structural stability between the upper cover 10 and the lower cover 20. This design allows the upper cover 10 to be opened and closed flexibly around the mounting hole of the handle 22, improving the ease of operation of the junction box.

[0058] The mounting holes are through holes at both ends of the handle 22, used to accommodate the mounting protrusions 12 of the top cover 10. The size and shape of the mounting holes match the mounting protrusions 12, ensuring a tight fit and hinged connection. The fit between the mounting holes and the mounting protrusions 12 provides a stable mechanical connection, enhancing the overall structural strength of the junction box. This design allows the top cover 10 to be opened and closed flexibly around the mounting holes, improving the ease of operation of the junction box.

[0059] The handle 22 is an integrated component on the lower cover 20, located on the side of the lower cover 20 away from the insertion hole 20d. Mounting holes are provided at both ends of the handle 22 for hinged engagement with the mounting protrusions 12 on the upper cover 10. The design of the handle 22 facilitates quick opening or closing of the junction box, improving operational convenience. Simultaneously, the structure of the handle 22 enhances the overall strength of the junction box, enabling it to better withstand external pressure and operating forces.

[0060] Through the above design, the junction box of this utility model achieves structural optimization, particularly in terms of ease of operation, structural stability, and assembly efficiency. The hinged design of the mounting protrusion 12 and the mounting hole, combined with the operating structure of the handle 22, not only improves the maintainability of the junction box but also enhances its overall structural strength. This design enables the junction box to maintain stable performance in complex outdoor environments, significantly improving the reliability and operating efficiency of the entire photovoltaic system while reducing maintenance costs.

[0061] In one embodiment, please refer to Figures 1 to 3 The bottom of the lower cover 20 is provided with two limiting protrusions 23 for installing the solar panel smart controller. The two limiting protrusions 23 are symmetrically arranged to limit the two sides of the solar panel smart controller.

[0062] The limiting protrusions 23 are protruding parts at the bottom of the lower cover 20, typically in the form of strips or blocks, located on both sides of the mounting cavity 20a. The two limiting protrusions 23 are symmetrically arranged to define the sides of the solar panel smart controller. The height and width of the limiting protrusions 23 are optimized according to the dimensions of the smart controller to ensure a tight fit between the two.

[0063] The junction box of this invention features structural optimization, particularly the symmetrically arranged limiting protrusions 23, which not only ensure accurate positioning and stable installation of the intelligent controller but also enhance the overall performance and reliability of the junction box. This design enables the junction box to maintain stable performance in complex outdoor environments, significantly improving the reliability and operating efficiency of the entire photovoltaic system while reducing maintenance costs.

[0064] In one embodiment, please refer to Figures 1 to 3The bottom of the lower cover 20 is also provided with multiple limiting posts 24, which are spaced apart. Each limiting post 24 is used to insert into the solar panel smart controller.

[0065] The limiting posts 24 are multiple protruding parts at the bottom of the lower cover 20, typically cylindrical or square columnar structures, spaced apart. The height and diameter of each limiting post 24 are designed according to the mounting hole specifications of the solar panel smart controller to ensure a tight fit between the two. There are four limiting posts 24, which are inserted into the mounting holes of the solar panel smart controller.

[0066] This embodiment, through the setting of the limiting post 24, not only ensures the accurate positioning and stable installation of the intelligent controller, but also enhances the overall performance and reliability of the junction box. This design enables the junction box to maintain stable performance in complex outdoor environments, significantly improving the reliability and operating efficiency of the entire photovoltaic system, while reducing maintenance costs.

[0067] The above description is merely an exemplary embodiment of the present utility model and does not limit the patent scope of the present utility model. Any equivalent structural transformations made based on the technical concept of the present utility model and the contents of the present utility model specification and drawings, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present utility model.

Claims

1. A junction box, characterized in that, The junction box includes: Top cover; and The lower cover is detachably connected to the upper cover. The lower cover has a mounting cavity and an air groove communicating with the mounting cavity. The mounting cavity is used to install the solar panel smart controller, and the air groove is used for potting adhesive and heat dissipation.

2. The junction box as described in claim 1, characterized in that, The air trough is an elongated arc-shaped trough.

3. The junction box as described in claim 1, characterized in that, The lower cover is also provided with multiple hollow structures that communicate with the mounting cavity. The multiple hollow structures are spaced apart from the air grooves, and the hollow structures are used for potting adhesive and heat dissipation.

4. The junction box as described in claim 3, characterized in that, Multiple hollow structures are arranged sequentially around the periphery of the lower cover.

5. The junction box as described in claim 3, characterized in that, The hollow structure includes at least three partitions connected in sequence. The three partitions are disposed on the inner wall of the lower cover and together with the inner wall of the lower cover form a glue-filling groove.

6. The junction box as described in claim 1, characterized in that, The lower cover is also provided with a plurality of wiring holes that communicate with the mounting cavity. The plurality of wiring holes are arranged along the same straight line and are spaced apart from the air groove.

7. The junction box as described in claim 1, characterized in that, The upper cover has at least two insertion protrusions on one side, and the two insertion protrusions are spaced apart; the lower cover has an insertion hole on one side of its outer wall, and each insertion protrusion is inserted into one insertion hole; the side of the upper cover away from the insertion protrusions is hinged to the side of the lower cover away from the insertion hole.

8. The junction box as described in claim 7, characterized in that, The upper cover has at least two mounting protrusions on the side away from the insertion protrusion, and the two mounting protrusions are spaced apart. A handle is provided on the side of the lower cover away from the insertion hole, and mounting holes are provided at both ends of the handle. Each mounting protrusion is hinged to a mounting hole.

9. The junction box as described in claim 1, characterized in that, The bottom of the lower cover is provided with two limiting protrusions for installing the solar panel smart controller. The two limiting protrusions are symmetrically arranged to limit the two sides of the solar panel smart controller.

10. The junction box as described in claim 9, characterized in that, The bottom of the lower cover is also provided with multiple limiting posts, which are spaced apart. Each limiting post is used to be inserted into the solar panel intelligent controller.

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